Stackable non-round plastic closure with a living hinge

ABSTRACT

A new and improved plastic closure is disclosed herein. The closure contains a breakout seal that leaves the opening flush with the wall of the closure, an interference fit lock for the seal, bypass walls to maintain freshness when the lid is closed, and induction heat sealing of the closure to the container.

I. BACKGROUND OF THE INVENTION

[0001] A. Field of the Invention

[0002] This application claims priority to U.S. Ser. No. 60/255,343,entitled Plastic Closure, filed Dec. 13, 2000. This invention relates tothe art of enclosures, and particularly plastic closures for compositecans, and even more particularly to plastic closures adapted for use onnon-round composite cans.

[0003] B. Description of the Related Art

[0004] Composite cans are made of multiple materials and contain apaper-based tube, a metal, plastic, or paper bottom closure, and metal,plastic, or paper top. In the past, the paper sidewalls of the cans weremade by winding adhesive coated paper around a mandrel. Recent advancesin machining have allowed the production of non-round containers to befaster and require less material. The non-round containers can bemanufactured with barrier properties for a variety of requirements.

[0005] The ability to create the containers, cost-effectively, withbarrier properties allows the containers to replace the existingbag-in-box packaging. The current closures for these non-roundcontainers fall short in convenience, style, and function.

[0006] The present invention provides a new and improved plastic closureand breakout seal and overcomes certain difficulties inherent in therelated inventions while providing better overall results.

[0007] C. Definitions

[0008] “Freshness seal”—a seal or fit that prevents static movement ofair.

II. SUMMARY OF THE INVENTION

[0009] In accordance with the present invention, the plastic closure isa one-piece design with a living hinge.

[0010] In accordance with another aspect of the present invention, theclosure is made of a thermoplastic resin that is compatible with abarrier layer, and the closure and the barrier layer can be boundtogether by induction heating, adhesive, or friction fit.

[0011] In accordance with still another aspect of the present invention,the breakout seal locks open by an interference fit.

[0012] In accordance with another aspect of the present invention, whenthe breakout seal is removed, the opening is flush with the internalwall.

[0013] In accordance with yet another aspect of the present invention,the closure has bypass walls for freshness sealing.

[0014] In accordance with another aspect of the present invention, theclosure is designed to allow easy and convenient stacking of thecontainers.

[0015] In accordance with another aspect of the present invention, anon-round plastic dispensing closure for a non-round compositecontainer, the closure includes a one-piece thermoplastic resin body,the body comprising a top side, a first top wall, a second top wall, thesecond top wall being concentrically larger than the first top wall, amiddle wall, the middle wall being concentrically larger than the secondtop wall, a bottom wall, the bottom wall extending circumferentiallydownward from the middle wall, the bottom wall being concentricallysmaller than the middle wall and concentrically larger than the firsttop wall, interference fit protrusions, bypass walls, and an openingthrough which contents of the associated container can be removedwithout removing the closure, a resealable flap, the flap connected tothe body by a living hinge, the flap comprising a latch, a lip, a firstwall, the first wall having a first shelf, a second wall, the secondwall having a second shelf, a third wall, the third wall having a thirdshelf, the first wall extending downwardly at substantially a 90° anglefrom the flap, the second shelf extending outwardly at a substantially90° angle to the first wall, the second wall extending downwardly at asubstantially 90° angle from the second shelf the third shelf extendingoutwardly at a substantially 90° angle from the second wall, the thirdwall extending downwardly at a substantially 90° angle from the thirdshelf, the third wall creating a freshness seal against the bypasswalls, and hinge sealing means, a tamper-evident break-out seal, whereinthe seal rotates approximately 180° with respect to the body, the seallocking open by interference fit with the interference fit protrusions,the seal, in the closed position, resting flush against the wall of thebody, the seal having reinforcement flanges, and an opening in the body,the opening having vertical walls, wherein once the seal is opened, noprotrusions on the vertical walls exist to inhibit removal of thecontents of the associated container.

[0016] In accordance with another aspect of the present invention, adispensing closure includes a body, the body having bypass walls, aresealable flap, the resealable flap connected to the body via a livinghinge, the resealable flap creating a freshness seal with the bypasswalls, and an opening, the resealable flap closing the opening.

[0017] In accordance with another aspect of the present invention, theclosure further includes a tamper-evident seal, the seal being capableof rotating substantially 180°, the seal being locked in the openposition via interference fit.

[0018] In accordance with another aspect of the present invention, theseal is flush against a wall opening in the closed position.

[0019] In accordance with another aspect of the present invention, thebody further includes a top side, a wall, the wall extendingcircumferentially downward from the top side, and interference fitprotrusions.

[0020] In accordance with another aspect of the present invention, theflap further includes a latch, a lip, and hinge sealing means.

[0021] In accordance with another aspect of the present invention, theflap further includes a first wall, the first wall having a first shelf,a second wall, the second wall having a second shelf, and a third wall,the third wall having a third shelf, the first wall extending downwardlyat substantially a 90° angle from the flap, the second shelf extendingoutwardly at a substantially 90° angle to the first wall, the secondwall extending downwardly at a substantially 90° angle from the secondshelf, the third shelf extending outwardly at a substantially 90° anglefrom the second wall, the third wall extending downwardly at asubstantially 90° angle from the third shelf, the third wall creating afreshness seal against the bypass walls.

[0022] In accordance with another aspect of the present invention, theclosure is non-round.

[0023] In accordance with another aspect of the present invention, theclosure is attached to a non-round composite container.

[0024] In accordance with another aspect of the present invention, adispensing container includes a composite body, the body having a top, abottom, at least one wall, and an opening, the opening being at the topof the composite body, and a closure, the closure covering the openingof the composite body the closure comprising a closure body, the bodyhaving bypass walls, a resealable flap, the flap connected to the bodyvia a living hinge, the flap creating a freshness seal with the bypasswalls, and an opening, the flap closing the opening.

[0025] In accordance with another aspect of the present invention, theclosure is attached to the container via one of the group comprising: 1)an adhesive; 2) friction fit; and, 3) induction sealing.

[0026] In accordance with another aspect of the present invention, theclosure is made of a material compatible with a barrier coating liningthe inside of the container.

[0027] Still other benefits and advantages of the invention will becomeapparent to those skilled in the art upon a reading and understanding ofthe following detailed specification.

III. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The invention is illustrated in the following drawings:

[0029]FIG. 1 is a side view of the inventive closure, showing thebreakout seal in the locked position;

[0030]FIG. 2 is a bottom view of the inventive closure, showing thereinforcement flanges on the breakout seal;

[0031]FIG. 3 is side view of the inventive closure, showing the breakoutseal in the closed position;

[0032]FIG. 4 is a front view of the inventive closure, showing the lidin the open position and showing the bypass walls;

[0033]FIG. 5 is a perspective view of the inventive closure, showing thebreakout seal being held in place by an interference fit;

[0034]FIG. 6 is a perspective view of the inventive closure;

[0035]FIG. 7 is a bottom perspective view of the inventive closure,showing the breakout seal locked in the open position;

[0036]FIG. 8 is a perspective view of a non-round container with theinventive closure on it;

[0037]FIG. 9A is a top view of the inventive closure in the closedposition;

[0038]FIG. 9B is a side view of the inventive closure in the closedposition;

[0039]FIG. 10A is an exploded cross-sectional view of section C of FIG.9B along line A-A of FIG. 9A, showing the hinge in the closed position;

[0040]FIG. 10B is an exploded view of section B of FIG. 9B, showing theconnection of the inventive closure in the closed position;

[0041]FIG. 11A is a top view of the inventive closure in the openposition;

[0042]FIG. 11B is a side view of the inventive closure in the openposition;

[0043]FIG. 12A is an exploded cross-sectional view of section C of FIG.11B along line A-A of FIG. 11A, showing the hinge in the open position;

[0044]FIG. 12B is an exploded view of section B of FIG. 11 B, showingthe connection of the inventive closure in the open position;

[0045]FIG. 13A is a top view of the inventive closure in the openposition;

[0046]FIG. 13B is a side view of the inventive closure in the openposition, showing the tamper evident seal locked in the open position;

[0047]FIG. 14 is an exploded cross-sectional view of section C of FIG.13B along line A-A of FIG. 13A, showing the hinge and the seal in theopen position;

[0048]FIG. 15 is a perspective view of the closure, showing the lid inthe open position and the seal in the closed position;

[0049]FIG. 16 is a perspective view of the inventive composite containerwith the closure in the closed position; and,

[0050]FIG. 17 is a perspective view of the inventive composite containerwith the closure in the open position and the seal in the closedposition.

IV. DESCRIPTION OF THE EMBODIMENTS

[0051] With reference now to FIGS. 1-8, a closure 10 has a body 12,which has a top 34, a bottom wall 14, a middle wall 56, first and secondtop walls 58, 60, a latch receiver 32, bypass walls 26, an opening 48,and an opening rim 20. In this embodiment, the opening 48 has a tamperevident seal 16, which covers the opening 48. The seal 16 has a seal lip46 for closing flush against opening rim 20, reinforcement flanges 22,and the seal 16 can be locked into place via interference fit wall 36.Also shown is lid 18, which has a latch 28, bypass wall receivers 30,first, second, and third walls 44, 54, 50, lid lip 52, and is connectedto the body 12 by a living hinge 24. The closure 10 is used, as shown inFIG. 8, on container 38.

[0052] With continuing reference to FIGS. 1, and 3-5, in thisembodiment, the closure 10 is rectangular-shaped, with rounded comers.The body 12, as mentioned above, has a top 34, the first and second topwalls 58, 60, the middle wall 56, and the bottom wall 14. The first topwall 58 extends downwardly, at substantially a 90° angle from the top34, the second top wall 60 extends outwardly then downwardly, atsubstantially a 90° angle from the first top wall 58. The second topwall 60 is concentric about the first top wall 58, the second top wall60 having a greater circumference. The first and second top walls 58, 60form a U-shape, ending at the lid 18 attached to the top 34. The middlewall 56 encompasses the entire dimensions of the closure 10, and extendsoutwardly then downwardly, at substantially a 90° angle from the secondtop wall 60. The middle wall 56 circumnavigates the entire closure 10and has a larger diameter than either the first or second top walls 58,60. The bottom wall 14 extends downwardly from the middle wall 56. Thebottom wall 14 circumnavigates the entire closure 14 and has a diametersubstantially the same as the second top wall 60. The bottom wall 14fits into the container 38 and middle wall 56 rests on the top edge ofthe container 38, as shown in FIGS. 16 and 17. The lid 18, when in theclosed position, continues the first and second top walls 58, 60 aroundthe closure 10. The design of the closure 10, in particular thearrangement of the walls 14, 56, 58, 60, is designed to allow theclosures 10 to be stackable one of top of the other. When stacked, thebottom wall 14 fits over the first and second top walls 58, 60, andrests against the middle wall 56.

[0053] It is to be understood that the preceding description is merelyone embodiment of this invention, and is not intended to limit it in anymanner. Any configuration or shape of closure can be used, as long aschosen using sound engineering judgment.

[0054] With continuing reference to FIGS. 4 and 5, the lid 18 has first,second, and third walls 44, 54, 50, and latch 28. The walls 44, 54, 50enable the lid 18 to create a freshness seal for the closure 10 thatprevents static movement of air. When the lid 18 is in the closedposition, walls 44, 54, 50 become the middle wall 56, second top wall60, and first top wall 58, respectively. The closure 10, in the area ofthe opening 48, has an interior wall 62, against which the second wall54 rests when the lid 18 is in the closed position. The lid 18 snapsinto place, thereby creating a freshness seal that prevents staticmovement of air. The first wall 44 overlaps the interior wall 62,thereby creating an extra seal to maintain freshness. It is to beunderstood that the particular configuration of the walls is notintended to limit the invention in any manner, and that anyconfiguration, chosen using sound engineering judgment, can be used.

[0055] The lid 18 closes completely against the rest of the closure 10,including the hinge 24 area of the lid 18. Currently, when lids areclosed, there is a space, or crack, remaining around the edges of thelid. This space allows air and moisture to enter the container 38 andthe contents do not remain fresh as long. In this embodiment, theclosure 10 has bypass walls 26 on either side of the closure 10,extending from first and second top walls 58, 60. The bypass walls 26extend out into the opening 48, so that when the lid 18 is closed, nospace or crack is left. The lid 18 is now sealed tightly and thecontents of the container 38 remain fresh longer. The bypass walls 26have a substantially similar configuration to the first and second walls44, 54 of the lid 18. The lid 18 has a bypass wall receiver 30, shown inFIG. 12A, that acts as the female end when the lid 18 is in the closedposition. The bypass wall receiver 30 has a substantially similar shapeas the bypass wall 26. The bypass wall receiver 30 receives the bypasswalls 26, and the lid 18 closes over the interior wall 62 in order tocreate a freshness seal that prevents the static movement of air. Theparticular configuration of the bypass walls and bypass wall receiverare merely one embodiment of this invention, and are not intended tolimit it in any manner. The bypass walls and bypass wall receivers canbe designed in any manner chosen using sound engineering judgment.

[0056] With reference now to FIGS. 9A-14, the closure 10 is shown inexploded format, showing the hinge 24 and the connection of the lid 18to the body 12. The lid 18 has a latch 28, which includes a latch finger40, which extends downwardly from the latch 28. The latch finger 40 isreceived by latch receiver 32, as shown in FIG. 10B and 12B. It is to beunderstood that the latch 28, latch receiver 32, and latch finger 40 aremerely one embodiment of this invention, and that any means ofconnecting the lid 18 to the closure 10 could be used, as long as chosenusing sound engineering judgment.

[0057] With reference now to FIGS. 13A, 13B, and 14, the closure 10 isshown with the seal 16 in the open position. The seal 36 has a seal lip46, which, when the seal 36 is the closed position, is flush against theinterior wall 62 of the opening 48. The seal 16 also is connected to thebody 12 via a living hinge 64. This seal living hinge 64 allows the seal16 to rotate approximately 160°. Depending on the thickness of the seal16, the seal 16 may rotate as much as approximately 180°. This rotationof the seal 16 prevents the seal 16 from falling into the container 38,while not interfering with the flow of contents from the container 38.The seal 16 can be any design or configuration, as long as chosen usingsound engineering judgment. In this embodiment, the seal 16 is held inthe open position by interference fit walls 36. The seal 16 is pusheddownwardly until an interference fit is accomplished between the seal 16and the walls 36.

[0058] In this embodiment, the tamper evident breakout seal 16 leaves anopening 48 that is flush with the internal wall 62 of the closure 10.The connection shown in FIGS. 9A-10B show the breakout seal 16 in theclosed position. The design of the seal 16, and the fact that the seal16 is attached to the closure 10 on the bottom of the seal 16 instead ofon the top of the seal 16, creates the flush opening 48. The flushopening 48 allows for easier and faster dispensing of the contents ofthe container 38.

[0059] In this embodiment, the closure 10 is a one-piece design made ofa thermoplastic resin material that is compatible with the material usedin barrier layers (not shown). It is to be understood however, that theclosure 10 may be made of any material chosen using sound engineeringjudgment. The closure 10 can be attached to the container 38 byadhesive, friction fit, induction sealing, or any other method chosenusing sound engineering judgment.

[0060] In another embodiment of this invention, if the closure 10 ismade of a material that is compatible with the barrier coating (such ascontainer lined with foil on the inside) the container 38 and closure 10may be sealed via induction heating. The barrier coating is not limitedto foil, but can be any barrier coating chosen using sound engineeringjudgment.

[0061] In another embodiment of this invention, the closure 10 does nothave a breakout seal 16. The container 38 may not need a seal 16, or aremovable internal foil seal (not shown) could be used when anadditional seal is needed.

[0062] It is to be understood that the invention is not limited tonon-round containers, but can be used on any container, as long aschosen using sound engineering judgment.

[0063] The invention has been described with reference to severalembodiments of the invention. Obviously, modifications and alterationswill occur to others upon a reading and understanding of thespecification. It is intended by applicant to include all suchmodifications and alterations insofar as they come within the scope ofthe appended claims or the equivalents thereof.

[0064] Having thus described the invention, it is now claimed:

What is claimed is:
 1. A non-round plastic dispensing closure for anon-round composite container, the closure comprising: a one-piecethermoplastic resin body, the body comprising: a top side; a first topwall; a second top wall, the second top wall being concentrically largerthan the first top wall; a middle wall, the middle wall beingconcentrically larger than the second top wall; a bottom wall, thebottom wall extending circumferentially downward from the middle wall,the bottom wall being concentrically smaller than the middle wall andconcentrically larger than the first top wall; interference fitprotrusions; bypass walls; and, an opening through which contents of theassociated container can be removed without removing the closure; aresealable flap, the flap connected to the body by a living hinge, theflap comprising: a latch; a lip; a first wall, the first wall having afirst shelf; a second wall, the second wall having a second shelf; athird wall, the third wall having a third shelf, the first wallextending downwardly at substantially a 90° angle from the flap, thesecond shelf extending outwardly at a substantially 90° angle to thefirst wall, the second wall extending downwardly at a substantially 90°angle from the second shelf, the third shelf extending outwardly at asubstantially 90° angle from the second wall, the third wall extendingdownwardly at a substantially 90° angle from the third shelf, the thirdwall creating a freshness seal against the bypass walls; and, hingesealing means; a tamper-evident break-out seal, wherein the seal rotatesapproximately 160° with respect to the body, the seal locking open byinterference fit with the interference fit protrusions, the seal, in theclosed position, resting flush against the wall of the body, the sealhaving reinforcement flanges; and, an opening in the body, the openinghaving vertical walls, wherein once the seal is opened, no protrusionson the vertical walls exist to inhibit removal of the contents of theassociated container.
 2. A dispensing closure comprising: a body, thebody having bypass walls; a resealable flap, the resealable flapconnected to the body via a living hinge, the resealable flap creating afreshness seal with the bypass walls; and, an opening, the resealableflap closing the opening.
 3. The closure of claim 2, wherein the closurefurther comprises: a tamper-evident seal, the seal being capable ofrotating substantially 180°, the seal being locked in the open positionvia interference fit.
 4. The closure of claim 3, wherein the seal isflush against a wall opening in the closed position.
 5. The closure ofclaim 4, wherein the body further comprises: a top side; a wall, thewall extending circumferentially downward from the top side; and,interference fit protrusions.
 6. The closure of claim 5, wherein theflap further comprises: a latch; a lip; and, hinge sealing means.
 7. Theclosure of claim 6, wherein the flap further comprises: a first wall,the first wall having a first shelf; a second wall, the second wallhaving a second shelf; and, a third wall, the third wall having a thirdshelf, the first wall extending downwardly at substantially a 90° anglefrom the flap, the second shelf extending outwardly at a substantially90° angle to the first wall, the second wall extending downwardly at asubstantially 90° angle from the second shelf, the third shelf extendingoutwardly at a substantially 90° angle from the second wall, the thirdwall extending downwardly at a substantially 90° angle from the thirdshelf, the third wall creating a freshness seal against the bypasswalls.
 8. The closure of claim 7, wherein the closure is non-round. 9.The closure of claim 8, wherein the closure is attached to a non-roundcomposite container.
 10. A dispensing container, the containercomprising: a composite body, the body having a top, a bottom, at leastone wall, and an opening, the opening being at the top of the compositebody; and, a closure, the closure covering the opening of the compositebody the closure comprising: a closure body, the body having bypasswalls; a resealable flap, the flap connected to the body via a livinghinge, the flap creating a freshness seal with the bypass walls; and, anopening, the flap closing the opening.
 11. The container of claim 10,wherein the closure further comprises: a tamper-evident seal, the sealbeing capable of rotating substantially 180°, the seal being locked inthe open position via interference fit.
 12. The container of claim 11,wherein the seal is flush against a wall opening in the closed position.13. The container of claim 12, wherein the closure body furthercomprises: a top side; a wall, the wall extending circumferentiallydownward from the top side; and, interference fit protrusions.
 14. Thecontainer of claim 13, wherein the flap further comprises: a latch; alip; and, hinge sealing means.
 15. The container of claim 14, whereinthe flap further comprises: a first wall, the first wall having a firstshelf; a second wall, the second wall having a second shelf; and, athird wall, the third wall having a third shelf, the first wallextending downwardly at substantially a 90° angle from the flap, thesecond shelf extending outwardly at a substantially 90° angle to thefirst wall, the second wall extending downwardly at a substantially 90°angle from the second shelf, the third shelf extending outwardly at asubstantially 90° angle from the second wall, the third wall extendingdownwardly at a substantially 90° angle from the third shelf, the thirdwall creating a freshness seal against the bypass walls.
 16. Thecontainer of claim 15, wherein the closure is non-round.
 17. Thecontainer of claim 16, wherein the container is a non-round compositecontainer.
 18. The container of claim 10, wherein the closure isattached to the container via one of the group comprising: 1) anadhesive; 2) friction fit; and, 3) induction sealing.
 19. The containerof claim 18, wherein the closure is made of a material compatible with abarrier coating lining the inside of the container.